Relay



y 7, 1960 T. J. OBSZARNY ET AL 2,937,249

RELAY 2 Sheets-Sheet 1 Filed May 31, 1955 INVENTORS.

May 17, 1960 T. .1. OBSZARNY ET AL 2,937,249

' RELAY Filed May 31, 1955 2 Sheets-Sheet 2 63 IN VEN TORS 55 m a 55 j} J BY 1 53 49 1W ATTORNEYS.

United States Patent() RELAY Thedore J. Obszarny and John Schmidt, Chicago, Ill

assignors to Guardian Electric Manufacturing Co., Clucago, lll., a corporation of Illinois Application May '31, 1955, Serial No. 512,150 '6 Claims. (Cl. 200-87) This invention relates to relays and more particularly to multiple contact electrically operated relays.

Electrical relays are frequently called upon to operate under very severe conditions with respect to physical acceleration or deceleration as a jet aircraft, or the like, and under conditions of heavy vibration. Such operating conditions require an extremely sturdy construction and balance of the parts and mounting thereof with severe restrictions on space. Relays are also frequently re quired to maintain relatively heavy contact pressure over a substantial period of time and must be constructed to dissipate the resultant heat.

It is oneof the objects of the present invention to provide a relay which is capable of satisfactory operation under extremely severe conditions of acceleration, vibration and continuous operation.

Another object is to provide a relay in which a plurality of contact pins are carried by a singlebead of insulating material, such as glass, which is sealed in a casing member.

Still another object is to provide a relay in which all .Of the operating parts of the relay are rigidly connected in a sub-assembly by spaced posts which also serve to secure the sub-assembly in a casing thus providing a rigid and sturdy mounting of the operating parts.

According to one feature of the invention, the casing is formed wit-h integral mounting flanges which not only provide maximum strength with minimum weight and space requirements, but also serve as efficient heat conductors for heat dissipation.

A further object is to provide a relay of the rotatable armature type in which the switches lie around the operating coil with elongated flexible contact strips extending parallel to the coil and connected to the rotating armature at their free ends.

According to one feature of the invention, the rotating armature is supported by a shaft journalled in hearings in spaced header and base plates between which the coil lies.

A. still further object is to provide a relay in which the header plate carries a hollow terminal block within which contact pins on the relay are connected respectively to contacts on the terminal block.

According to a feature of the invention, the terminal block is formed of insulating material with integral upwardly extending barriers between adjacent contacts to minimizethe possibility of short-circuit-ing.

The above and other objects and features of the invention will be more readily apparent from the following description when read in connection with the accompanying drawings, in which:

Figure 1 is a perspective view of a relay embodying the invention with the relay parts disassembled from the casing:

Figures 2 and 3 are cross sections through the casing on the lines 2-2 and '3-3 respectively of Figure l;

' Figure 4 is a view partly in section and partly in elevation illustrating connection of the terminal block, the header plate and the casing;

Figure 5 is a plan view of the header plate with the terminal block removed;

Figure 6 is a section on the line 66 of Figure 5;

Figure 7 is a central section through the operating coil assembly;

Figure 8 is a perspective disassembled view of the base plate and magnetic core strip;

Figure 9 is an elevation of the relay operating assembly looking from the bottom in Figure 7;

Figure 10 is atop plan view of the terminal block; and

Figure 11 is a section on the broken line 11-11 of Figure 10.

The relay of the present invention provides a plurality of double throw switches which are normally moved to one contact position when the relay operating coil is de-energized and which are moved to another contact position when the operating coil is energized. The switches are assembled in a header and base plate assembly which also carries magnetic operating means for moving the switches. The header and base plate assembly is received in a supporting and enclosing casing which may be hermetically sealed if desired and the header plate carries a terminal block through which external circuit connections can conveniently be made to the relay. The several parts of the assembly are described in detail hereafter.

The switch construction The switch construction, as shown in detail in Figures 5, and 6 and generally in Figures 1 and 9, comprises a header plate 10 which is preferably rectangular in outline and which is formed with a narrow flange 11 at its edge to facilitate assembly with the casing and terminal block. The header plate may be made of a metal, such as steel. Near the corners of the header plate openings 12 are provided to receive switch assemblies and the center portion of the header plate is formed with similar openings 13 through which terminals for energizing the relay coil may extend, as shown at 14. The terminals 14 are embedded in insulating blocks 15 formed of glass, or the like, which may be secured and sealed in the header plate in the manner more particularly describedand claimed in the co-pending application of Thedore I. Obszarny, Serial No. 500,409, filed April 11, 1955. Q

In the relay as shown there are four switches each of which is mounted in one of the openings 12 in the header plate 10. As best seen in Figures 5 and 6, eachopening 12 receives a relatively large insulating head 16 of glass, or the like, which may be secured in the opening 12 in the same manner as the beads 15 are secured in the openings 13. Each bead 16 carries three contact pins, two of which, as shown, at 17, extend straight through the bead and are provided with spaced facing contacts 18 at their inner ends. The third contact pin 19 extends through the bead and has a bent over flattened end 21 to which a flexible contact strip 22 is secured by rivets, or the like. The strip 22 carries a double contact 23 lying between the spaced contacts 18 selectively to en gage them. The strip may normally be biased into engagement with one of the contacts 18, as shown in Figure 6, or it may normally occupy a centered position between the contacts 18 to be flexed selectively into engage ment therewith by the operating mechanism described hereinafter.

The header and base plate assembly The header plate with the switches and terminals i4 assembled thereon is connected in spaced parallel relation to a base plate 24, as seen in Figures 1, 7, 8 a nd 9'." The 'base plate '24, as best seen in Figure 8, is of generally rectangular outline with its sides recessed to provide clearance for operation of the switches and with its corners formed with mounting openings 25.

The header, plate and, baseplate are rigidly connected by' four corner posts 26 which extend into openings in the header plate, as seen in Figure 7, and are secured thereto by brazing or soldering, as indicated at 27. The

opposite ends of the pins 28 are shouldered and have reduced extensions 28 extending through theIopenings 25 in the base plate. The extensions 28 are preferably threaded beyond the base plate to receive internally threaded sleeves 29 which secure the base plate to the pins with the base and header plates in spaced parallel relationship. The sleeves 29 project substantially beyond the base plate for mounting the header and base plate in the casing, as described hereinafter. The header and base plates are assembled with the contact pins 17 and 21 and the flexible contact strips 22 extending from header toward the base plate, the contact pins 22 proecting beyond the base plate along the recessed sides thereof, as seen in Figure 9.

The magnetic operating means The space between the header and base plate receives magnetic coils for operating the switches from one position to the other when the coils are energized. For this purpose, the base plate carries magnetic posts 31 extending therefrom toward the header plate and formed of soft iron or similar magnetic material. At their ends the posts 31 are formed with enlarged pole pieces 32 which extend through the base plate and have flattened parallel faces thereon, as best seen in Figure 9. At their upper ends adjacent the header plate the posts 31 are reduced as indicated at 33, to fit through openings in a core piece 34 which completes a magnetic circuit at the spaced upper ends of the posts. After inserting the reduced ends of the posts through openings in the core piece 34, the ends of the posts may be riveted over as seen in Figure 7. Preferably the posts are also internally threaded to receive screws 35 which extend through the base plate to asslst in holding the base and header plates assembled.

- The pole pieces 32 are adapted to attract a rotatable armature 33 which is mounted for rotation about its center at the center of the base plate and which has flat end portions to engage the flat faces of the pole pieces 32 when the pole pieces are magnetized. The armature 33 is supported on a shaft 36 which extends through central openings in the base plate and the core piece 34 and is journalled therein.

With'this construction, the armature shaft is supported on widely spaced bearings so that the possibility of binding is eliminated and the armature is allowed to turn freely on an accurately positioned axis.

The armature is normally urged to the position shown in Figure 9 away from the pole pieces by a coil spring 37 and is turned in the opposite direction against the 'coil spring by the magnetic attraction of the pole pieces tacts 18 and a slight additional distance to flex the contact strips 22 to maintain tight contact engagement.

The pole pieces are adapted to be energized by windings 38. As shown, the windings 38 are wound on bobbins 39 of an insulating material, such as paper, which are of a size to slip over the posts 31. The bobbins are assembled on the posts before the core piece 34 is mounted and are firmly held in position thereby. The windings 38 are preferably connected together in series and are connected to the terminals 14 to be energized by an external control voltage when desired. Due to this arrangement of the windings a maximum number of effective turns can be provided in minimum space so that a high degree of magnetic force can be developed with a minimum applied voltage and in minimum space requirements.

To actuate the switches when the armature is turned to one position or the other, the armature carries a disc 41 of insulating material, such as impregnated fiber or the like. The disc 41 is provided adjacent its periphery with four slots 42 into which the flexible contact strips 22 respectively extend. The disc 41 may be riveted or otherwise fixedly secured to the armature to turn therewith when the armature turns.

With this construction, the flexible contact strips 22 can be inserted in the slots 42 in the disc 41 at the same time the base and header plates are assembled together without requiring any separate assembly operations for the switch actuating mechanism. The armature and coils may also be assembled at the same time so that when the header and base plates are connected by the posts 26 and the screws 35 a complete sub-assembly is provided ready for mounting in the casing.

The casing assembly The operating parts of the relay, as described above, are adapted to be mounted in an enclosing casing 43 which is preferably integrally die cast or similarly formed.

"The casing, as shown, is rectangular in outline of a size as indicated at 44, the parts preferably being tinned to facilitate soldering.

To secure the assembly in the casing, the threaded sleeves 29 are made of a length to rest against the bottom of the casing which is provided with openings 45 to register with the threaded sleeves as best seen in Figure 2. Screws may be inserted through the openings 45 and threaded into the sleeves 29 securely to mount the parts in the casing, the exterior of the casing being recessed, as shown at 46 in Figure 3, to receive the heads of the screws so that there are no projecting parts and so that the screws can be sealed by solder, or the like, where hermetic sealing is desired. With the parts so assembled, the casing itself, other than for its bottom which may be reinforced, and for its mounting flanges, is not relied on to hold the operating relay parts assembled, the posts 26 serving this purpose, so that the casing may be relatively light and of a size just suflicient to enclose the operating parts of the relay.

For'mounting the casing, it is formed at two of its opposite sides with integral mounting flanges 47 which are preferably cast or otherwise formed integral with the casing walls, as shown in Figures 2 and 3. The flanges '47 formed in this manner provide maximum physical strength for mounting and at the same time are in intimate heat conducting relationship with the casing walls so that heat generated during operation of the relay will be dissipated with maximum efficiency. The provision of flanges on two edges of the casing, as shown, not only increases the flexibility of mounting of the unit, but also leaves one flange at each side projecting openly into the atmosphere for maximum heat dissipation.

block overthe header plate for connection of external circuits to the relay. The header block, as shown in vFigures l, 4, 10 and 11, is preferably a hollow cup-shaped block 48 molded or otherwise formed. of insulating material, such as plastic or impregnated fiber. The terminal block has'a relatively narrow edge flange 49 which is of a size and shape to fit over the header plate 10 against the flange 11, as shown in Figure 1, to seal the interior of the terminal block securely against the header plate. The terminal block is held in place by integral internally threaded posts 51 on the header plate which receive mounting screws 52 extending through the top of the terminal block.

.Thei'terminal block is provided with a plurality of spaced terminals 53 which may be arranged in double rows with one row above and laterally spaced from the other, as best seen in Figures 10 and 11. Each terminal comprises a metallic clip member threaded to receive a fastening screw 54 and extending through the upper surface of the terminal block. The clip members may be formed with openings 55 therethrough through which conductors can extend to be soldered. The conductors from the terminals are connected respectively to the switch contact pins 17 and 19 within the hollow terminal block to complete circuits to the various switches. The leads 14 may be soldered to certain of the terminals, as for example the two terminals nearest the center of the terminal block, as seen in Figure 10, for connection to a controlling circuit to energize the coils when desired.

In order to minimize or eliminate possibility of accidental short-circuiting, the upper and lower rows of terminals are offset horizontally with respect to each other, as seen in Figure 10. In addition, the terminal block is formed with integrally molded upstanding barriers 56 between adjacent terminals in the same row to prevent the ends of the wires connected to the terminals from contacting each other. With this arrangement, it will be noted that a wire extending to a terminal in the upper bank directly overlies one of the barriers 56 in the lower bank thereby further minimizing the possibility of shortcircuiting and facilitating connection of wires to the terminals.

With the relay completely assembled, a control circuit may be connected to the terminals to which the leads 14 are connected to energize the solenoid under external control at desired times. Circuits to be controlled by the relay may be connected to the remaining terminals in the desired combinations so that certain circuits will be completed when the relay is tie-energized and other circuits will be completed when the relay is energized.

Due to the fact that the flexible contact strips are bent to press the contacts tightly together and due to the fact that the armature and the entire relay construction is balanced about the shaft 36, the relay is substantially immune to acceleration or vibrational forces. The contacts will thus be tightly maintained under all installation conditions.

Mounting of the relay operating parts independent of the casing provides maximum strength and contributes to the arrangement such that a minimum of mounting space is required. Furthermore, the mounting and the construction of the casing contribute to heat conduction so that the relay will withstand severe service conditions without overheating.

While one embodiment of the invention has been shown and described herein, will be understood that it is illustrative' only and not to be taken as a definition of the scope of the invention, reference being had for this purpose to the appended claims.

What is claimed is:

1.- A relay comprising a header plate, a magnetic core hognted in the central portion of the header plate and r wterminating 1n a magnetic pole remote from the header plate, a base plate secured to the header plate in spaced parallel relation thereto and adjacent to the pole, an armature shaft extending through and journalled adjacent to its opposite ends respectively in the header and base plates, an armature carried by the shaft adjacent to the 'base plate to turned by magnetic attraction of thepole,

an insulating disc carried by the armature and formed with a series of slots, and a plurality of switches carried by the header plate around the core and each including an elongated flexible blade secured at one end to the header plate and extending beside the core to and beyond the base plate with its free end fitting into'one of the slots in the insulating disc.

2. A relay comprising a header plate, a base plate secured to the header plate in spaced parallel relation therewith, a U-shaped magnetic core mounted between the header and base plates with the ends of its legs extending through the base plate and defining poles symmetrically spaced about the center of the base plate, windings on the legs of the core to magnetize it, an armature shaft journalled adjacent to its opposite ends respectively centrally in the header plate and base plate and extending between the legs of the core, an armature carried by the shaft adjacent to the base plate with its ends lying adjacent to the poles to be attracted thereby when the windings are energized, an insulating disc carried by the armature having slots in its periphery and a plurality of switches carried by the header plate each including a flexible contact secured at one end to the header plate and extending beside the core and windings to and beyond the base plate with its free end fitting into one of the slots.

3. A relay comprising spaced parallel header and base plates, a plurality of spaced posts rigidly connecting the header and base plates and extending beyond the base plate, a magnetic coil unit mounted between the plates and having poles adjacent to the base plate, an armature rotatably mounted adjacent to the base plate to be turned by magnetic attraction of the poles, switch means carried by the header plate around the coil unit and including elongated operating means extending beside the coil unit and engaging the armature to be moved thereby as the armature turns, and a casing open at one end and closed at the other to receive the assembly with the header plate closing the open end of the casing and with the extensions of the posts engaging and secured to the closed end of the casing.

4. The construction of claim 3 in which the casing includes integral outwardly extending mounting brackets to mount the casing securely and to transfer heat therefrom.

5. A relay comprising a container open at one end and closed at the other, a header plate sealingly closing the open end of the container, a plurality of contact pins extending through the plate and insulated therefrom, means at one side of the header plate within the container including a magnetic coil to complete circuits selectively between certain of the contact pins, a cupped terminal block fitting sealingly against the other side of the header plate including a plurality of terminals connected respectively to the contact pins and formed for connection to conductors, and means to secure the terminal block to the header plate with the edge of the terminal block seating against the edge portion of the header plate.

6. A relay comprising spaced parallel header and base plates, a plurality of spaced posts rigidly connecting the header and base plates and extending beyond the base plate, a magnetic coil unit mounted between the plates and having poles adjacent to the base plate, an armature rotatably mounted adjacent to the base plate to be turned by magnetic attraction of the poles, switch means carried by the header plate around the coil unit and including elongated operating means extending beside the coil unit and engaging the armature to be moved thereby as the armature turns, a casing open at one end and closed at the other to receive the assembly with the header plate closing the open end of the casing and with the extensions of the posts engaging and secured to the closed end of the casing, the switch means including contact pins extending through the header plate, a cupped terminal block mounted with its open side facing and sealingly engaging *7 the outer surface of the header plate, a plurality of contacts extending through the base of the terminal block to' the header plate.

References Cited in the file of this patent UNITED STATES PATENTS 1,998,822 Ronci et al Apr. 23, 1935 2,090,170 Wilms et a1 Mar. 22, 1938 8 'Vio1 June 12, 1951 Miloche Apr. 1, 1952 Miller July 13, 1954 Anderson Sept. 28, 1954 Somers Sept. 20, 1955 Hall et a1. Oct. 16, 1956 Lazich Dec. 25, 1956 Horman Jan. 15, 1957 FOREIGN PATENTS Great Britain Feb. 15, 1921 Great Britain May 12, 1954 

